advanced cfb technology for utilization of standardized srf · advanced cfb technology for...
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Advanced CFB technology for utilization of
standardized SRF
Juha Sarkki
Foster Wheeler
RECOMBIO final conference
June 13, 2013, Helsinki
Foster Wheeler AG, Business Groups
The Global Engineering & Construction (E&C) Group
The Global Power Group
1
Designing, constructing, and managing projects for some of the
world´s largest process plants in a wide range of industries, including
oil and gas, chemicals, and pharmaceuticals.
Designing, manufacturing, and erecting a full line of boilers, and
environmental products for utility, industrial, and cogeneration
clients. A world-leading expert in combustion technology.
RECOMBIO final conference June 13, 2013, Helsinki
Foster Wheeler Global Power Group Offices
Management and support operating unit HQs and/or main engineering centre
Regional/local engineering centre
Sales offices
Denver, CO
Espoo
Norrköping
Varkaus
Krefeld
Madrid
Warsaw
Tarragona
Sosnowiec
Shanghai
Xinhui
Beijing
Bangkok
Colton
Martinez
Camden
Petrox
Ban Chang
Santiago
A global business with approximately 3,000 highly-skilled people
Hanoi
Manufacturing facilities (GPG)
Power plant operation
Kurikka
Friedrichsdorf
2
St. Louis, MO
Phoenix, AZ
Charlotte, NC
Atlanta, GA
Clinton, NJ
Univ. of Minnesota
Melbourne, FL
McGregor, TX
Pittsburgh, PA
Chicago, IL
Houston, TX
Al-Khobar
RECOMBIO final conference June 13, 2013, Helsinki
World Leader in Fluidized Bed Combustion
(CFB) Technology
• First BFB boilers delivered in the 1970s, and world’s first CFB boiler supplied in 1979.
• World’s first once-through supercritical CFB boiler started operation in 2009 in Lagisza, Poland.
• Flexi-Burn® - air/oxy flexible CFB boiler commercially available by the end of 2013.
• CFB boiler fuel flexibility and multifuel capability provide for efficient utilization of fossil and
renewable fuels.
• 111 Biomass CFB boilers (full biomass and co-combustion)
• Biggest units under construction 550 MWe Benson supercritical CFBs for coal in Korea
136 - Bubbling fluidized bed (BFB) boilers 411 - Circulating fluid bed (CFB) boilers
• 375 delivered
• 36 under construction
• Biggest unit in operation 460 MWe
• 136 delivered
11 - Atmospheric fluidized bed gasifires
• 11 delivered
PKE Lagisza, Poland Äänevoima Oy, Finland Lahti Energia, Finland
3 RECOMBIO final conference June 13, 2013, Helsinki
Foster Wheeler Global Power Reference Base
2,533 Units - over 220 GWe
Circulating Fluidized Bed (CFB) Boilers Waste Heat Boilers
Heat Recovery Steam Generators
Bubbling Fluidized Bed (BFB) Boilers PC Boilers
Gasifires
4
Total Sold FW Units
Units MWe
PC 331 109,801
CFB 411 31,854
Oil & Gas 324 41,462
HRSG 410 26,290
Industrial 1,007 14,445
Solar 50 2,209
Total 2,533 220,061
RECOMBIO final conference June 13, 2013, Helsinki
Kauttua 65 MWth, 25 kg/s, 83 barg, 500 C
Co-firing REF with wood residue, peat and coal
Burn tests of used packaging in 1992-1993
RECOMBIO final conference June 13, 2013, Helsinki
Fuel map in 1998
RECOMBIO final conference June 13, 2013, Helsinki
Heating
Value,
MJ/kg
20
35
0
5
10
PEAT
BARK
- PLY -
WOOD
SEWAGE
SLUDGE
BIO &
FIBER
SLUDGE
&
S
ANTRACITE
COAL
WOOD BIOMASS
DEMOLITION
WOOD
CHIP-
BOARD -
POLYOLEFIN
PLASTICS
(PE, PP, PC..)
COLORED
OR
PRINTED
PLASTICS,
CLEAN
COLORED
OR
PRINTED
MIXED
PLASTICS
RDF
CONSUMER
SRF
MIXED
PLASTICS
PAPER &
WOOD
PETROLEUM COKE
DEINKING
SLUDGE SEWAGE
SLUDGE
REF
PELLETS
WOOD &
PLASTICS
SRF
COMMERCIAL
&
INDUSTRIAL
BITUMINOUS
COAL
ANTRACITE
COAL
BIO &
FIBER
SLUDGE
BROWN COAL,
LIGNITE
PLY-
WOOD
Burning Difficulty
WASTE
COAL
OIL
SHALE
CFB Fuel
Range
CFB Technology opens the door to
Fuel Flexibility and Carbon Neutral Fuels
RECOMBIO final conference June 13, 2013, Helsinki
Fuel class
Ste
am
para
mete
rs
Söderenergi -
IKV
• Demolition wood up to 100 %
• REF < 25% – CFB
– IntrexTM
– Short empty pass
– Easily exchangable superheaters
Easy fuel Challenging
fuel
• RDF&REF
– CFB
– Intrextm
– Easily exchangable superheaters
– Empty pass
– Water cannons in empty pass
– Stoker fuel feeding
– Spring hammer SH soot blowing
Lomellina II
• Bio fuels with low portion of recycled fuels
– BFB/CFB
Mälarenergi
• Demolition wood up to 100 % – CFB
– IntrexTM
Prokon Nord
FW’s multiple Boiler Concepts for waste fuels and biomass
RECOMBIO final conference June 13, 2013, Helsinki
CFB-
Concept
for SRF
and
RDF >30 CFB references for
co-firing various
types of waste
Lomellina I (2000) and II (2007)
RDF 59 MWSt, 24.1 kg/s, 62 bar, 443ºC
Högdalen (2000)
REF 91 MWSt, 31.8 kg/s, 60 bar, 480ºC
Viken Energinett (2001)
SRF (selected high calorif. ind. fractions) 34.5 MWt, 16 bar, 204ºC
10 Altholz plants in Germany,
Holland and Belgium (1996-2010) 60-100 MWSt, 90 bar, 520ºC
Design Basis of FW CFB Concept for waste fuels
RECOMBIO final conference June 13, 2013, Helsinki
Multifuel CFB for Waste and Clean Biomass (CHP) Igelsta (Söderenergi AB, Södertälje)
240 MWth, 73 MWe-net, 209 MWDH, 92 kg/s, 90 bar, 540 C
Emissions 6%O2, dry
NOx [mg/MJ] 35*
SO2 [mg/m3n] 75
CO [mg/m3n] 50*
Dust [mg/m3n] 10
NH3 ppm 10
TOC [mg/m3n] 10
HCl / HF [mg/m3n] 10 / 1
Cd+Tl / Hg / HMs [mg/m3n] 0.05 / 0.05 / 0.5
PCDD+F [ng/m3n] 0.1
*) only at 100% load with Mix 1, 2, and 3
Fuel Mix 1 Mix 2 Mix 3
Biomass [%]LHV 75 30 100
Rec.wood [%]LHV 0 70 0
REF pellets [%]LHV 25 0 0
Moisture [%]ar 44.3 35.6 50.0
Ash [%]dry 6.5 4.7 4.0
Nitrogen [%]dry 0.6 0.8 0.5
Sulfur [%]dry 0.09 0.08 0.06
Chlorine [ppm]dry 1200 800 200
LHV [MJ/kg]ar 9.7 11.0 8.3
Total plant efficiency ~110%LHV 90%HHV
RECOMBIO final conference June 13, 2013, Helsinki
Refuse Delivered Fuel (RDF)
0.3 % ds
0.9 % ds
27%
14.3%
12.9 MJ/kg
FUEL DATA
Sulphur
Chlorine
Moisture
Ash (as received)
LHV (as received)
DESIGN PERFORMANCE, O2 11% in dry gases Flue Gas Exit Temperature Boiler Efficiency Emissions - NOx
- CO
168 °C 90.2% < 35 mg/MJ < 50 mg/Nm³
RDF FIRED CFB BOILER E.ON Värme Sverige AB, Norrköping, Sweden
85 MWth, 30 MWe, 31 kg/s, 66 bar, 450 C
- Biomass based combustible fraction is 60 % of RDF
RECOMBIO final conference June 13, 2013, Helsinki
Dust
CO
SO2
NO2
Total C
HCl
HF
Cd, Tl
Hg
Heavy metals: Sb, As, Pb, Cr, Co, Cu, Mn, Ni, V, Sn
PCDD/PCDF
10
50
50
200
10
10
1
0.05
0.05
0.5
0.1
mg/Nm³
Emission permit values
RECOMBIO final conference June 13, 2013, Helsinki
Fuel feeding
RECOMBIO final conference June 13, 2013, Helsinki
Intrex SH
RECOMBIO final conference June 13, 2013, Helsinki
Spring Hammers: Idle pass & Horizontal pass
RECOMBIO final conference June 13, 2013, Helsinki
Gas
flow
FEATURES:
•spring anvil raises the
frequency but conveys
high impact force
• sequence controlled
(10 blows at a time - waiting
time adjusted)
• no steam consumption
Tube bank with FW-spring hammer cleaning
RECOMBIO final conference June 13, 2013, Helsinki
Bottom Ash Removal System
Bottom ash removal system:
• Discharge chutes
• Water-cooled bottom ash screws
• Rotating Screen
• Coarse material from screento
bottom ash container
• Reinjection of fine material to
furnace
RECOMBIO final conference June 13, 2013, Helsinki
Heating value of SRF vs time
0
5000
10000
15000
20000
25000
30000
9.9.2007 19.9.2007 29.9.2007 9.10.2007 19.10.2007 29.10.2007
Date
Calc
ula
ted
& a
naly
se
d L
HV
[k
J/k
g]
RECOMBIO final conference June 13, 2013, Helsinki
Combustion
Technology:
Fuel spec
Boiler supplier in flow chain for SRF
RECOMBIO final conference June 13, 2013, Helsinki
• Common definition of SRF for the supplier and the customer
• Improved understanding of SRF as fuel
• Improved business environment for WtE applications
• Model for good practice
• Link between waste and power
• Testing methods for characterization of SRF
• Tools for quality assurance
• Product improvement and development
SRF standard in use
RECOMBIO final conference June 13, 2013, Helsinki
• Standards provide tools for SRF with consistent quality and quantified
properties
• Foster Wheeler CFB technology is a proven solution for SRF in power
generation with high steam parameters and with good emission
performance
Take Away
RECOMBIO final conference June 13, 2013, Helsinki
www.fwc.com